US8607911B2 - Moving shelf equipment - Google Patents

Moving shelf equipment Download PDF

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Publication number
US8607911B2
US8607911B2 US13/257,914 US200913257914A US8607911B2 US 8607911 B2 US8607911 B2 US 8607911B2 US 200913257914 A US200913257914 A US 200913257914A US 8607911 B2 US8607911 B2 US 8607911B2
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Prior art keywords
travel
movable rack
widthwise shift
movable
widthwise
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US13/257,914
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US20120006765A1 (en
Inventor
Kazushi Tsujimoto
Natsuo Takagawa
Syouji Yokoyama
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Daifuku Co Ltd
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Daifuku Co Ltd
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Assigned to DAIFUKU CO., LTD. reassignment DAIFUKU CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TAKAGAWA, NATSUO, TSUJIMOTO, KAZUSHI, YOKOYAMA, SYOUJI
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
    • B65G1/02—Storage devices
    • B65G1/04—Storage devices mechanical
    • B65G1/10—Storage devices mechanical with relatively movable racks to facilitate insertion or removal of articles
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D1/00—Control of position, course, altitude or attitude of land, water, air or space vehicles, e.g. using automatic pilots

Definitions

  • the present invention relates to a movable rack system to be installed in a narrowly limited space, for example in a warehouse, namely a movable rack system having a plurality of movable racks that can travel freely back and forth on a travel path by means of wheels. Especially it relates to a movable rack system allowing movable racks to travel freely back and forth without being guided by a rail (in a trackless manner).
  • Patent Literature 1 An example of a conventional movable rack system allowing free reciprocating trackless traveling is disclosed in Patent Literature 1.
  • such a system where a plurality of movable racks that can travel freely back and forth on a travel path (in a trackless manner) by means of wheels are disposed between stationary racks, so that a corridor is opened up between the adjacent stationary rack and a movable rack or between adjacent movable racks by the travels of the movable racks, and goods are delivered to/from the stationary rack or the movable rack, which face the corridor.
  • Wheels located at both sides of each movable rack in the left and right direction, which is perpendicular to the extending direction of the travel path, are respectively provided with driving motors to constitute driven travel wheels. Further, pulse encoders are disposed at both the sides and a movable rack controller is also provided to control the drive rotation amount of both the driving motors, respectively.
  • the movable rack controller counts pulses of the respective pulse encoders to determine the travel distances of the respective driven travel wheels at both the sides, determines the deviation and the change rates of the travel distances, and controls the speeds of the respective driving motors (the drive rotation amount) so as to eliminate the deviation of the predictive travel distances predicted from the deviation and the change rates of the travel distances, so that the attitude of the movable rack is maintained without being skewed during the travel (execution of attitude control).
  • the attitude control is executed by the movable rack controller during the reciprocating travels of the movable rack along the travel path, so that skewing of the movable rack during the travel and narrowing of the corridor to disturb the goods delivery can be prevented even in the trackless condition.
  • a sheet rail member to be detected is laid on the floor surface along the travel path, and a widthwise shift detecting means is equipped to detect a deviation in the left and right direction (a widthwise shift) of the movable rack by detecting the member.
  • the movable rack controller controls the speeds (drive rotation amount) of the respective driving motors to eliminate the widthwise shift, so that the movable rack does not deviate in the left and right direction (execution of widthwise shift control).
  • a sheet rail member to be detected is used to eliminate the widthwise shift, however, it is troublesome to construct such a sheet rail member along a definite lane keeping it horizontally on the floor surface. Further, since the sheet rail member to be detected is exposed on the corridor surface in the place where the corridor is formed, it must be guarded against damages caused by treading by workers or a service vehicle for delivering goods, but such robust construction is difficult to form.
  • the present invention has for its object to provide a movable rack system, where the widthwise shift control of the movable rack can be conducted without using a sheet rail member to be detected.
  • the invention according to claim 1 of the present application is a movable rack system, which comprises a plurality of movable racks that can travel freely back and forth on a travel path by means of wheels, among which the wheels located at both sides in the transverse direction of the travel path are respectively provided with driving motors to constitute driven travel wheels, and a control means for controlling a travel of the movable rack by driving the respective driving motors of the movable rack, the system comprising; members to be detected being provided on a floor surface at stop positions of the respective movable racks; and widthwise shift detection means being provided on the respective movable racks for detecting a widthwise shift of the movable rack from the travel path in the left and right direction perpendicular to the extending direction of the travel path by detecting the members to be detected; wherein the control means detects the widthwise shift by the widthwise shift detection means when the rack stops to travel, and wherein when a detected widthwise shift exceeding a pre-determined value is detected, the control means determine
  • the members to be detected are detected when the movable rack stops to travel, and when the detected widthwise shift exceeds the pre-determined value, a travel route for the movable rack is determined so as to reduce the widthwise shift, and the rotation speeds of the respective driving motors are controlled to correct the widthwise shift of the rack so that the rack follows the travel route at the next travel.
  • a travel route to reduce the widthwise shift is determined, and the rotation speeds of both the driving motors are controlled so that the rack traces the travel route without light reflective tape or magnetic tape along the travel path as in the conventional art.
  • the widthwise shift control for the movable rack can be conducted without using a sheet rail member to be detected, and therefore it is not required to lay down such any sheet rail member to be detected.
  • control means controls the system such that when a movable rack travels according to the travel route reducing the widthwise shift, another movable rack starts to travel with a delay of a pre-determined time period.
  • the travel route is so configured that both the driving motors are initiated with above a pre-determined rotation speed and driven thereafter at differentiated rotation speeds to eliminate the widthwise shift by a travel of the rack over a pre-determined distance.
  • both the driving motors are initiated with above a pre-determined rotation speed and driven thereafter at differentiated rotation speeds, and the widthwise shift of the movable rack is eliminated by the travel of the rack over a pre-determined distance. Since both the driving motors are initiated with above a pre-determined rotation speed, when one wheel is stopped and the other wheel is moved about the one, such a phenomenon can be avoided that the one wheel is dragged to move uncontrollably.
  • the travel route is so configured that both the driving motors are initiated with above a pre-determined rotation speed and driven thereafter at differentiated rotation speeds to eliminate the widthwise shift by plural travels of the movable rack.
  • both the driving motors are initiated with above a pre-determined rotation speed and driven thereafter at differentiated rotation speeds, and the widthwise shift of the movable rack is eliminated during the plurality of travels of the rack.
  • control means determines the frequency or the number of executions of the travels reducing the widthwise shift, and when the frequency exceeds a pre-determined frequency, or if the number exceeds a pre-determined number the control means issues an alarm.
  • magnets are disposed as the members to be detected at respective forward and backward stop positions of the respective movable racks that move along the travel path and stop there; while magnetic sensors are equipped so as to face the magnets as the widthwise shift detection means; and when the movable rack stop to travel, the control means detects the widthwise shift of the movable rack from the change between the magnetic intensity currently detected by the magnetic sensors and the magnetic intensity previously detected by the magnetic sensors, and executes the travel control for the movable rack to reduce the widthwise shift thereof.
  • the widthwise shift of the movable rack is detected by comparing the magnetic intensities of the magnets disposed at respective forward and backward stop positions of the rack, which are detected by the magnetic sensors, and the travel of the movable rack is controlled to reduce the detected widthwise shift of the movable rack.
  • the respective movable racks are equipped with a travel distance measuring means for detecting travel distances of the respective driven travel wheels at both the sides; and the control means performs an attitude correction control for the movable rack by controlling the driving rotation amount of the respective driving motors to eliminate the deviation in the travel distances of both the driven travel wheels based on the travel distances of the driven travel wheels detected by the travel distance measuring means.
  • control means of the movable rack controls the rotation amount of the respective driving motors so as to eliminate the deviation between the travel distances of both the driven travel wheels based on the travel distances of the driven travel wheels, which are detected by the two travel distance measuring means at both the sides, and thus a travel of the movable rack is controlled to prevent a skewed attitude thereof.
  • the widthwise shift of the movable rack can be corrected by such an arrangement that when the widthwise shift exceeds a pre-determined value at a time when the movable rack stops to travel, a travel route for the movable rack is determined to reduce the widthwise shift, and the rotation speeds of the respective driving motors are controlled so that the movable rack follows the travel route at the next travel thereof. Consequently, it becomes not necessary to construct a light reflective tape or a magnetic tape along the travel path, and therefore, any inconveniences associated with the construction thereof can be advantageously eliminated.
  • the movable rack system of the embodiment is configured of six movable racks 11 (an example of a plurality of racks) and stationary racks 3 disposed outward at both the ends of a travel path 10 for the group of the movable racks 11 .
  • the 6 movable racks 11 are installed between the pair of the stationary racks 3 movable freely back and forth along the travel path direction A, and a work corridor S is formed between the movable racks 11 or between the movable rack 11 and the stationary rack 3 for delivery of goods to/from a movable rack 11 or a stationary rack 3 .
  • the width of the work corridor S in the travel path direction A is identical with the width of a movable rack 11 in the travel path direction A.
  • the direction perpendicular to the travel path direction A (the forward-backward direction) of the movable racks 11 is referred as a transverse direction B (the left and right direction).
  • a transverse direction B the left and right direction.
  • the right direction is referred as a forward direction (FW) and the movement to the right side as an advancing direction
  • the left direction is referred as a backward direction (RE) and the moving direction to the left side as a retreating direction.
  • one of the sides (the back side) of the movable rack 11 in the transverse direction B (the left and right direction) is referred as HP side, and the other side (the front side) in the transverse direction B as OP side.
  • the backward stop position is referred as an RV stop position and the forward stop position as an FW stop position
  • the stationary rack 3 is constituted of a lower frame unit 4 , which is mounted and fixed on the floor surface 1 a , and a rack unit 5 mounted on the lower frame unit 4 .
  • a rack unit 5 mounted on the lower frame unit 4 .
  • the rack unit 5 are formed a plurality of storage compartments 5 a both in horizontal and vertical directions.
  • the photoelectric sensor 6 is a transmission type photoelectric switch constituted of a light emitter 7 and a light receiver 8 aligned facing each other, and they are arranged such that a detection beam 7 a from each light emitter 7 passes through the space between the bottom surface of lower frame unit 12 (described below) in the group of the movable racks 11 and the floor surface 1 a , to be received by a light receiver 8 at the opposite position.
  • the movable rack 11 By installing a pair of stationary racks 3 , goods can be stored utilizing the facility space at high efficiency. Further, by using the photoelectric sensors 6 , if the movable rack 11 is attempted to move while a worker is within the work corridor S, the worker can be detected by the detection beam 7 a crossing the work corridor S, and the movement of the movable rack 11 can be controlled to stop. Furthermore, since the detection beam 7 a is set at a lower level from the floor surface 1 a , not only the worker but also a small foreign substance, which may fall down from a rack unit 5 of a stationary rack 3 or a rack unit 13 of the movable rack 11 (described below) onto the work corridor S, can be detected in a non-physically contacted manner.
  • photoelectric sensors may be arranged at the front and back sides of the movable rack 11 so that the detection beams are directed in the transverse direction B, or contact bumpers may be provided at the lower portions of both the forward and backward surfaces of the movable rack 11 .
  • a plurality of the movable racks 11 are installed so that they can travel back and forth freely by means of travel wheels 14 (an example of travel support devices; wheels) on the travel path 10 .
  • the movable rack 11 is configured with a lower frame unit 12 and a rack unit 13 mounted thereon.
  • the lower frame unit 12 is configured in the form of a rectangular frame with lateral lower frames 12 a located at both the ends thereof in the transverse direction B (left and right direction), intermediate lower frames 12 b arranged at 5 locations (plural locations) inside thereof, connecting members 12 c connecting the lateral lower frames 12 a and the intermediate lower frames 12 b in the transverse direction B (left and right direction), longitudinal connecting members 12 d placed at a plurality of positions between the connecting members 12 c in the fore and aft direction, and a plurality of braces 12 e.
  • the lateral lower frame 12 a and the intermediate lower frame 12 b are respectively configured of a pair of side plates and a top plate being connected to the upper edges of the side plates to form a portal frame which opens downward.
  • the connecting member 12 c and the longitudinal connecting member 12 d are tubular members with a rectangular cross-section.
  • the rack unit 13 is configured with trusses 13 a , beams 13 b , subbeams 13 c and braces 13 d erected on the lateral lower frame 12 a and the intermediate lower frame 12 b to form a framework. Therefore, a plurality of storage compartments 13 e , which open to the travel direction A, are formed in the vertical direction as well as in the transverse direction B. The uppermost storage compartments 13 e are also open upward.
  • a pair of front and backward travel wheels 14 are mounted by means of wheel shafts 15 , respectively.
  • the travel wheel 14 is configured with an inner wheel 14 a made of a metal and an outer wheel 14 b made of a hard urethane rubber, and rolls on freely over a floor surface 1 a of the floor 1 made of, for example, concrete by means of the outer wheel 14 b .
  • the travel wheels 14 are provided at 7 positions (plural positions) in the transverse direction B and 2 positions (plural positions) in the travel direction A, respectively.
  • the travel wheels 14 located at both the sides in the transverse direction B of the travel path 10 are configured as driven travel wheels 14 A (driven travel support devices) provided with rotation drive means, respectively. Namely, among the travel wheels 14 group supported by the lateral lower frame 12 a at the sides of the travel path 10 in the transverse direction B, at least one travel wheel 14 situated at one of the sides in the travel direction A (at least one) is mounted on the drive wheel shaft 15 A to constitute a driven travel wheel 14 A.
  • the driven travel wheels 14 A mounted at both the sides in the transverse direction B are provided at 2 positions being straight and opposite each other in the transverse direction B with respect to the lower frame unit 2 of the rectangular frame.
  • the drive wheel shaft 15 A extends inward in the transverse direction B, to the innermost end of which a travel wheel supported by the adjacent intermediate lower frame 12 b is connected. Then the travel wheel also constitutes a driven travel wheel 14 A.
  • induction driving motors 16 an example of rotation drive means having reduction gears, respectively.
  • the driving motors 16 are mounted on the intermediate lower frames 12 b.
  • cylindrical stoppers 17 made of rubber.
  • the above-mentioned items 12 to 17 , etc. constitute a movable rack 11 that is freely movable reciprocatingly on the travel path 10 .
  • pulse encoders 21 are installed near the inner driven travel wheel 14 A (supporting/driving device) on the sides in the transverse direction B, respectively, and the pulse encoders 21 are connected to a control panel 20 mounted on the side surface of the movable rack 11 .
  • the pulse encoder 21 is constituted of: a supporting frame 24 , which is swingable up and down about a transverse axis 23 along the transverse direction B, provided on a bracket 22 extended from the lower frame unit 12 ; a detection wheel unit 27 whose wheel unit shaft 26 is supported through bearings 25 freely rotatably on the supporting frame 24 ; a rotating unit 28 mounted on the wheel unit shaft 26 ; a photoelectric switch 29 mounted on the supporting frame 24 side facing slits 28 a and 28 b formed on the rotating unit 28 , etc.
  • the photoelectric switch 29 is composed of an outer photoelectric switch 29 a facing the outer slit 28 a and an inner photoelectric switch 29 b facing the inner slit 28 b . Both the photoelectric switches 29 a and 29 b are connected to the control panel 20 .
  • the pressure contact of the detection wheel unit 27 to the floor surface 1 a is realized by descent of the supporting frame 24 by its own weight.
  • any biasing means such as helical compression spring or leaf spring, may be used to make the supporting frame 24 descend downward.
  • the items 22 to 29 , etc. mentioned above constitutes an example of the pulse encoder 21 .
  • round shaped magnets 31 are buried on each HP side and OP side to indicate the RV stop position, as well as additional round shaped magnets 31 (an example of members to be detected) are buried being shifted in the travel direction A (fore and aft direction) on each HP side and OP to indicate the FW stop position.
  • Each movable rack 11 is equipped with magnetic sensors 35 as a widthwise shift detection means to know the widthwise shift of the movable rack 11 by detecting the magnets 31 at an HP position and an OP position.
  • a bracket 36 that approaches the floor 1 in the transverse direction B and the bracket carries three magnetic sensors 35 a (HP side), 35 b (center), and 35 c (OP side) in the transverse direction B (left and right direction).
  • the central magnetic sensor 35 b is so positioned to face the magnet 31 upward when the movable rack 11 is not deviated in the transverse direction B.
  • the 2 sets of the magnetic sensors 35 a , 35 b and 35 c are connected to the control panel 20 .
  • the proximity sensors 37 a and 37 b are connected to the control panel 20 .
  • the proximity sensors 37 a and 37 b may be magnetic sensors, reflective photoelectric switches, or ultrasonic sensor.
  • the control panel 20 installed on each of the movable rack 11 is connected to a main control panel 38 .
  • the main control panel 38 is for controlling the entire movable rack system, equipped with an ON/OFF switch for the movable rack system, an operating unit (buttons) for each movable rack 11 , etc.
  • a travel direction signal is given to the control panel 20 of the movable rack 11 to be moved as a travel command.
  • the main control panel 40 is manipulated so that the travel command signal (travel direction signal) is given to the control panel 20 of the movable rack 11 standing at the stop position P 5 .
  • the main control panel 38 is so configured that, in case a plurality of the movable racks 11 are moved simultaneously, it can control them to start one-by-one at a predetermined time intervals (2 to 3 sec). Furthermore, when giving the travel direction signal, which requires widthwise shift control in the traveling direction as will be described below, a widthwise shift control signal indicating the presence of the movable rack to be controlled is given.
  • each movable rack 11 in the control panel 20 of each movable rack 11 are provided an operation panel 40 ( FIG. 9 ), a movable rack controller 41 (an example of the control means) composed of a computer, and vector control inverters 42 a and 42 b for controlling the respective torque vectors of the driving motors 16 disposed along the transverse direction B (left and right direction) according to the commanded speed value output from the movable rack controller 41 ; and on the surface of the control panel 20 of each movable rack 11 are provided an alarm lamp 43 that lights up when a deviation in the transverse direction B (herein referred to as “widthwise shift”) is not eliminated automatically, and a caution lamp 44 that lights up when the widthwise shift occurs frequently with a movable rack 11 .
  • an alarm lamp 43 that lights up when a deviation in the transverse direction B (herein referred to as “widthwise shift”) is not eliminated automatically, and a caution lamp 44 that lights up when the widthwise shift occurs frequently with a movable rack 11 .
  • the vector control inverters 42 a and 42 b are so configured that the output can be calculated with a high speed computing units (CPU) in accordance with the then prevailing loads, the voltage/current vectors can be optimally controlled, and the starting torques are increased.
  • the torque vectors By controlling the torque vectors using the vector control inverters 42 a and 42 b , rotational driving influenced little by load fluctuation can be conducted, minimizing an oblique movement caused by the imbalance in the load distribution of the stored goods in the movable rack 11 .
  • the movable rack controller 41 carries out a correction control to eliminate the widthwise shift (widthwise shift control), automatically (more particulars will be described below).
  • a manual operation panel 40 is also provided, just in case such correction control be not started. As shown in FIG. 9 , the operation panel 40 provides:
  • an automated/forced selection switch 51 for selecting an automated operation of the movable rack 11 or a forced travel thereof with the aid of the switches described below;
  • an HP turn switch 52 (a switch for operating one of the driven travel wheels 14 A manually) to activate the driving motor 16 connected to the driven travel wheel 14 A on the HP side such that the driven travel wheel 14 A is driven to the direction to which the switch is tilted;
  • an OP turn switch 53 (a switch for operating the other driven travel wheel 14 A manually) to activate the driving motor 16 connected to the driven travel wheel 14 A on the OP side such that the driven travel wheel 14 A is driven to the direction to which the switch is tilted;
  • an HP shift button switch 54 (an example of a 1st switch to start a semi-automatic correction by a predetermined distance to the HP side) for sending a command to shift the movable rack 11 to the HP side in the transverse direction (left and right direction) by a predetermined width (e.g. 10 mm);
  • an OP shift button switch 55 (an example of a 2nd switch to start a semi-automatic correction by a predetermined distance to the OP side) for sending a command to shift the movable rack 11 to the OP side in the transverse direction (left and right direction) by a predetermined width (e.g. 10 mm).
  • the movable rack controller 41 As shown in FIG. 11 , to the movable rack controller 41 are connected the main control panel 38 , the operation panel 40 , the HP and OP pulse encoders 21 (photoelectric switches 29 a and 29 b ), the HP and OP magnetic sensors 35 a , 35 b and 35 c , the forward and backward proximity sensors 37 a and 37 b , the HP and OP vector control inverters 42 a and 42 b , the alarm lamp 43 and the caution lamp 44 . And, the movable rack controller 41 comprises:
  • a forced travel control unit 61 (more details will be described below);
  • an HP magnetic intensity detection unit 62 a where the magnetic intensities detected by the respective HP magnetic sensors 35 a , 35 b and 35 c are summed up to determine the magnetic intensity at the HP side, and the magnetic intensities at the HP side detected by the magnetic sensor 35 a and those at the OP side detected by the magnetic sensor 35 c are compared to know the direction of the widthwise shift of the movable rack 11 (deviated to the HP side or to the OP side);
  • an OP magnetic intensity detection unit 62 b where the magnetic intensities detected by the respective OP magnetic sensors 35 a , 35 b and 35 c are summed up to determine the magnetic intensity at the OP side;
  • a travel reset unit 64 where a travel start pulse signal is output when a travel command from the automated travel judgment unit 63 is switched to an advancing command or a retreating command;
  • a first counter 65 that is reset when a reset signal (as will be described below) is input and the advancing command is output from the automated travel judgment unit 63 , where pulses output from the left pulse encoder 21 is counted and then the travel distance per pulse (which has been learned beforehand) is multiplied to obtain the travel distance of the left driven travel wheel 14 A (an example of the travel amount);
  • a second counter 66 that is reset when a reset signal (as will be described below) is input and the advancing command is output from the automated travel judgment unit 63 , where pulses output from the right pulse encoder 21 is counted and the travel distance per pulse (which has been learned beforehand) is multiplied to obtain the travel distance of the right driven travel wheel 14 A (an example of the travel amount);
  • a pulse error judgment unit 67 that is reset by a travel start pulse signal output from the travel reset unit 64 , where pulses output respectively from the left and right pulse encoders 21 is counted to detect the difference in the two pulse numbers; and when the difference exceeds a determined value (variable), a predictive control execution signal is output (made ON), and when the difference of the pulse numbers returns to approximately zero, the predictive control execution signal is made OFF;
  • a first differentiator 68 where the travel distance of the left driven travel wheel 14 A detected by the first counter 65 is differentiated, and then multiplied with a coefficient described below to obtain the (marginal) travel distance during a definite time period of the left driven travel wheel 14 A;
  • a first adder 69 where the travel distance of the left driven travel wheel 14 A detected by the first counter 65 is added to the (marginal) travel distance during a definite time period of the left driven travel wheel 14 A obtained by the first differentiator 68 to obtain a predictive travel distance after the definite time;
  • a second differentiator 70 where the travel distance of the right driven travel wheel 14 A detected by the second counter 66 is differentiated, and then multiplied with a coefficient described below to obtain the (marginal) travel distance per during a definite time period of the right driven travel wheel 14 A;
  • a second adder 71 where the travel distance of the right driven travel wheel 14 A detected by the second counter 66 is added to the (marginal) travel distance during a definite time period of the left driven travel wheel 14 A obtained by the second differentiator 70 to obtain a predictive travel distance after the definite time period;
  • a first subtractor 72 where the travel distance of the right driven travel wheel 14 A detected by the second counter 66 is subtracted from the travel distance of the left driven travel wheel 14 A detected by the first counter 65 to obtain a travel distance deviation between the left and right driven travel wheels 14 A;
  • a second subtractor 73 where the predictive travel distance after the definite time period of the right driven travel wheel 14 A obtained by the second adder 71 is subtracted from the predictive travel distance after the definite time period of the left driven travel wheel 14 A obtained by the first adder 69 to obtain a predictive travel distance deviation between the left and right driven travel wheels 14 A;
  • a timer 74 that starts counting the time triggered by a travel start pulse signal output from the travel reset unit 64 , stops counting the time by a predictive control execution signal output from the pulse error judgment unit 67 , and outputs the aforementioned coefficient that is inversely proportional to the obtained time, namely a coefficient based on the trend until the difference of the pulse numbers (the travel distance deviation) exceeds a predetermined value;
  • a speed control unit 75 (more details will be described below).
  • a forced travel control unit 61 to a forced travel control unit 61 are input operational signals of the respective switches 51 to 55 on the operation panel 40 and forward and backward approach signals detected by the forward and backward proximity sensors 37 a and 37 b , respectively; and a “forced” selection signal is output to a speed control unit 75 when “forced” is selected by the automated/forced selection switch 51 , and an “automated” selection signal is output to the speed control unit 75 when “automated” is selected.
  • HP turn switch 52 is tilted to the forward side (FW side) during when “forced” is selected by the automated/forced selection switch 51 , an HP motor forward driving signal is output to the speed control unit 75 , and if the same is tilted to the backward side (RE side), an HP motor backward driving signal is output to the speed control unit 75 .
  • the OP turn switch 53 is tilted to the forward side (FW side)
  • an OP motor forward driving signal is output to the speed control unit 75
  • an OP motor backward driving signal is output to the speed control unit 75 .
  • the backward forced HP widthwise shift correction command signal and the backward forced OP widthwise shift correction command signal are reset; and when the approach signal of the forward proximity sensor 37 a is activated, the forward forced HP widthwise shift correction command signal and the forward forced OP widthwise shift correction command signal are reset.
  • the automated travel judgment unit 63 To the automated travel judgment unit 63 , are supplied the travel direction signal and the presence signal for widthwise shift control are input from the main control panel 38 , the magnetic intensity at the HP side from the HP magnetic detection unit 62 a , the magnetic intensity at the OP side from the OP magnetic detection unit 62 b , and the approach signal of the adjacent movable rack 11 of the forward and backward proximity sensors 37 a and 37 b .
  • the unit judges if the movable rack 11 should be moved forward or backward by the travel direction signal, outputs an advancing command or a retreating command with a time delay, in case the presence signal for widthwise shift control is present; and outputs a stop command is output when the approach signal from the proximity sensor 37 a or 37 b in the travel direction is present or the magnetic intensity is detected at the HP side or at the OP side. Furthermore, although not illustrated, when the photoelectric sensor 6 is activated, it also outputs a stop command.
  • a speed control unit 75 comprises a forced driving unit 77 , a semi-automatic widthwise shift control unit 78 , an automatic attitude controller 79 and an automatic widthwise shift control unit 80 .
  • speed value commands for the left and right vector control inverters 42 a and 42 b (corresponding to the driving rotation speed by the rotation driving means) is obtained based on forced travel command signal etc.
  • the control unit 75 further outputs an alarm signal to the alarm lamp 43 , a caution signal to the caution lamp 44 , and a widthwise shift control execution signal to the main control panel 38 .
  • a relay RY-FOR activated by the “forced” selection signal output from the forced travel control unit 61 and a relay RY-AUTO activated by the “automated” selection signal output from the forced travel control unit 61 .
  • a relay RY-W that is activated, when relay RY-W-OP is ON, or RY-W-HP is ON in accordance with the output of the automatic widthwise shift control unit 80 .
  • a relay RY-HP-FW activated when an HP motor forward driving signal of the forced travel control unit 61 is input
  • a relay RY-HP-RE activated when an HP motor backward driving signal of the forced travel control unit 61 is input
  • a relay RY-OP-FW activated when an OP motor forward driving signal of the forced travel control unit 61 is input
  • a relay RY-OP-RE activated when an OP motor backward driving signal of the forced travel control unit 61 is input.
  • an HP speed setter 81 set at the commanded speed value for the HP driven travel wheel 14 A at manual operation
  • an OP speed setter 82 set at the commanded speed value for the OP driven travel wheel 14 A at manual operation.
  • the commanded speed value for the HP driven travel wheel 14 A set at the HP speed setter 81 is output by the operation of the relay RY-HP-FW and the value attaching a minus sign to the commanded speed value for the HP driven travel wheel 14 A is output by the operation of the relay RY-HP-RE.
  • the commanded speed value for the OP driven travel wheel 14 A set at the OP speed setter 82 is output by the operation of the relay RY-OP-FW and the value attaching a minus sign to the commanded speed value for the OP driven travel wheel 14 A is output by the operation of the relay RY-OP-RE.
  • the commanded speed value constitutes an advancing commanded speed value if it is positive, and a retreating commanded speed value if it is negative.
  • the relay RY-HP-FW is activated to output the positive (advancing) commanded speed value for the HP driven travel wheel 14 A set at the HP speed setter 81 , so that the HP driven travel wheel 14 A is driven forward by the HP driving motor 16 .
  • the relay RY-HP-RE is activated to output the (retreating) commanded speed value for the HP driven travel wheel 14 A attaching a minus sign to the commanded speed value set at the HP speed setter 81 , so that the HP driven travel wheel 14 A is driven backward by the HP driving motor 16 .
  • the relay RY-OP-RE is activated to output the (retreating) commanded speed value for the OP driven travel wheel 14 A attaching a minus sign to the commanded speed value set at the OP speed setter 82 , so that the OP driven travel wheel 14 A is driven backward by the OP driving motor 16 .
  • the movable rack 11 can be turned as shown in FIGS. 10 (A) and (B). That is, when “forced” is selected by the automated/forced selection switch 51 , if the HP turn switch 52 is tilted forward (FW side) and the OP turn switch 53 backward (RE side) as shown in FIG. 10 (A), the HP driving motor 16 is directly driven to drive forward the HP driven travel wheel 14 A, and the OP driving motor 16 is directly driven to drive backward the OP driven travel wheel 14 A, so that the movable rack 11 becomes skewed to the HP side. Contrary, if the HP turn switch 52 is tilted backward (RE side) and the OP turn switch 53 forward (FW side) as shown in FIG. 10 (B), the movable rack 11 skews with the OP side.
  • a relay RY-WS-HP-RE activated when a backward forced HP widthwise shift correction command signal of the forced travel control unit 61 is input
  • a relay RY-WS-HP-FW activated when a forward forced HP widthwise shift correction command signal of the forced travel control unit 61 is input
  • a relay RY-WS-OP-RE activated when a backward forced OP widthwise shift correction command signal of the forced travel control unit 61 is input
  • a relay RY-WS-OP-FW activated when a forward forced OP widthwise shift correction command signal of the forced travel control unit 61 is input.
  • a relay RY-WS that is activated when a relay RY-WS-HP-RE is activated, or a relay RY-WS-HP-FW is activated, or a relay RY-WS-OP-RE is activated, or a relay RY-WS-OP-FW is activated.
  • a 1st speed commander 83 that starts to output a pre-set commanded speed value for one of the driven travel wheels 14 A when a relay RY-WS is activated
  • a 2nd speed commander 84 that starts to output a pre-set commanded speed value for the other driven travel wheel 14 A when a relay RY-WS is activated.
  • a commanded speed value output from the 1st speed commander 83 when a relay RY-WS-OP-FW is activated a commanded speed value output from the 2nd speed commander 84 when a relay RY-WS-HP-FW is activated
  • a negative commanded speed value output from the 1st speed commander 83 when a relay RY-WS-OP-RE is activated a negative commanded speed value output from the 2nd speed commander 84 when a relay RY-WS-HP-RE is activated.
  • a commanded speed value output from the 2nd speed commander 84 when a relay RY-WS-OP-FW is activated a commanded speed value output from the 1st speed commander 83 when a relay RY-WS-HP-FW is activated
  • a negative commanded speed value output from the 2nd speed commander 84 when a relay RY-WS-OP-RE is activated a negative commanded speed value output from the 1st speed commander 83 when a relay RY-WS-HP-RE is activated.
  • a positive commanded speed value means the commanded speed value for advancing
  • a negative value means the commanded speed value for retreating
  • the commanded speed values output from the 1st speed commander 83 and the 2nd speed commander 84 will be described below.
  • a travel route of the movable rack 11 is determined to eliminate a pre-determined width of the widthwise shift during when the rack travels the width of the work corridor (travel direction), for example 2m, as indicated by FIG. 17 (B) (an example to decrease the widthwise shift).
  • travel direction for example 2m
  • FIG. 17 (B) an example to decrease the widthwise shift
  • the time series of the rotation speeds (commanded speed values) of the HP driving motor 16 and the OP driving motor 16 are computed for realizing the travel route; the 1st speed commander 83 is set at the time series of the rotation speeds (commanded speed value) of one of the driving motors 16 (at the HP side in the current embodiment); and the 2nd speed commander 84 is set at the time series of the rotation speeds (commanded speed value) of the other driving motor 16 (at the OP side in the current embodiment).
  • the pre-determined width is limited to the physically adjustable range, which is defined by the maximum rotation speed and the speed change attainable by the driving motors 16 while the movable rack 11 travels across the width of the work corridor S.
  • the movable rack 11 is first translated parallel, namely both the driving motors 16 are started simultaneously at a rotation speed above the pre-determined rotation speed (the rotation speed at which both the HP and OP driven travel wheels 14 A do not slip); then the movable rack 11 is, while travelling, skewed to the direction to eliminate the widthwise shift by the angle as indicated in FIG.
  • the widthwise shift to be eliminated by one operation of the HP shift button switch 54 and the OP shift button switch 55 is set at 1 ⁇ 2 of the width corrected by a travel across the width of the work corridor S (the maximum width). Therefore, the maximum width can be eliminated by two-time operations.
  • the open side of the movable rack 11 (the side where the work corridor S is formed and the movable rack 11 can travel alone) is determined by the approach signal output by the proximity sensor 37 a or 37 b and a forward or backward forced HP widthwise shift correction command is generated to activate the relay RY-WS-HP-FW or the relay RY-WS-HP-RE, as shown in FIG. 12 .
  • a commanded speed value is output from the 2nd speed commander 84 to the HP vector control inverter 42 a according to the travel route
  • a commanded speed value is output from the 1st speed commander 83 to the OP vector control inverter 42 b according to the travel route.
  • the driving motors 16 at the HP and OP sides are driven, so that the movable rack 11 advances along the travel route as shown in FIG. 10 (C), and the movable rack 11 moves to the HP direction by the pre-determined width.
  • a negative (reverse direction) commanded speed value is output from the 2nd speed commander 83 to the HP vector control inverter 42 a according to the travel route
  • a negative (reverse direction) commanded speed value is output from the 2nd speed commander 84 to the OP vector control inverter 42 b according to the travel route.
  • the driving motors 16 at the HP and OP sides are driven, so that the movable rack 11 retreat along the travel route as shown in FIG. 10 (C), however in the opposite direction with respect to the fore and aft direction A, and the movable rack 11 moves to the HP side by the pre-determined width.
  • a commanded speed value is output from the 1st speed commander 83 to the HP vector control inverter 42 a according to the travel route
  • a commanded speed value is output from the 2nd speed commander 84 to the OP vector control inverter 42 b according to the travel route.
  • the driving motors 16 at the HP and OP sides are driven, so that the movable rack 11 advances and moves to the OP side by the pre-determined width as the travel route shown in FIG. 10 (D).
  • a negative commanded speed value is output from the 1st speed commander 83 to the HP vector control inverter 42 a according to the travel route
  • a negative commanded speed value is output from the 2nd speed commander 84 to the OP vector control inverter 42 b according to the travel route.
  • the driving motors 16 at the HP and OP sides are driven, so that the movable rack 11 retreats along the travel route as shown in FIG. 10 (D), however in the opposite direction with respect to the fore and aft direction A, and the movable rack 11 moves to the OP side by the pre-determined width.
  • a relay RY-F activated when a travel command signal of the automated travel judgment unit 63 is an advancing command (to be output with time-delay if the widthwise shift control signal is present), a relay RY-B activated when the same is a retreating command (to be output with time-delay if the widthwise shift control signal is present), a relay RY-S activated when the same is a stop command, and a relay RY-M activated when the predictive control execution signal from the pulse error judgment unit 67 is ON.
  • a speed setter 85 for a pre-determined travel speed of the movable rack 11 . It is so configured that, according to the action of a relay RY-M, the travel distance deviation is selected if the predictive control execution signal is not present, and the predictive travel distance deviation is selected if the predictive control execution signal is present. Further, a 1st function unit 86 is provided to calculate a speed adjustment amount for the HP driven travel wheel 14 A, as well as a 2nd function unit 87 to calculate a speed adjustment amount for the OP driven travel wheel 14 A, both based on the selected deviation.
  • the 1st function unit 86 When the positive deviation value exceeds the positive pre-determined value (dead band), the 1st function unit 86 outputs a positive corrective speed value proportional thereto; and when the negative deviation value exceeds the negative pre-determined value (dead band), the 2nd function unit 87 outputs a negative corrective speed value proportional thereto.
  • the 1st function unit 86 or the 2nd function unit 87 outputs a corrective speed value to execute the movable rack attitude control (skewing correction control).
  • the automatic attitude controller 79 further comprises a 3rd subtractor 88 that subtracts the positive corrective speed value output from the 1st function unit 86 from the pre-determined travel speed of the movable rack 11 set at the speed setter 85 to obtain the commanded speed value for the HP driven travel wheel 14 A; and a 1st low limiter 89 that limits the lower limit of the commanded speed value for the HP driven travel wheel 14 A obtained by the 3rd subtractor 88 to assure the lowest speed.
  • the lower-limited commanded speed value for the HP driven travel wheel 14 A is selected by the operation of relay RY-F (activated by an advancing command), the low-limited commanded speed value for the HP driven travel wheel 14 A inverted to a negative value is selected by the operation of relay RY-B (activated by a retreating command); and “0” is selected as the commanded speed value for the HP driven travel wheel 14 A by the operation of relay RY-S (activated by a stop command), so that the commanded speed value is output to the HP vector control inverter 42 a.
  • the automatic attitude controller 79 further comprises a 4th subtractor 90 that subtract the corrective speed value output from the 2nd function unit 87 from the pre-determined travel speed of the movable rack 11 set at the speed setter 85 to obtain the commanded speed value for the OP driven travel wheel 14 A; and a 2nd low limiter 91 that limits the lower limit of the commanded speed value for the right driven travel wheel 14 A obtained by the 4th subtractor 90 to assure the lowest speed.
  • the low-limited commanded speed value for the OP driven travel wheel 14 A is selected by the operation of relay RY-F (activated by an advancing command), the low-limited commanded speed value for the OP driven travel wheel 14 A inverted to a negative value is selected by the operation of relay RY-B (activated by a retreating command), and “0” is selected as the commanded speed value for the OP driven travel wheel 14 A by the operation of relay RY-S (activated by a stop command), so that the commanded speed value is output to the OP vector control inverter 42 b.
  • the speed setter 85 If an advancing command or a retreating command is input from the main control panel 38 , the speed setter 85 outputs a commanded speed value, which is positive at advancing and negative at retreating, to the HP vector control inverter 42 a and the OP vector control inverter 42 b to move the movable rack 11 . If a stop command is input from the main control panel 38 , the commanded speed value of “0” is output to the HP vector control inverter 42 a and the OP vector control inverter 42 b to stop the movable rack 11 .
  • the travel distance deviation of the driven travel wheels 14 A is detected by two pulse encoders 21 at both the sides and the counters 65 and 66 , based on which the deviation of the travel distances of both the driven travel wheels 14 A is calculated and input.
  • the commanded speed values output from the speed setter 85 are corrected to eliminate the deviation and the differentiated commanded speed values are output to the HP vector control inverter 42 a and the OP vector control inverter 42 b to correct the driving rotation speeds of the respective driving motors 16 to control the attitude of the movable rack 11 .
  • a predictive travel distance is calculated based on the travel distance and the time elapsed from the start of the travel until the difference in the accumulated pulse counts exceeds the pre-set value, and a control signal is output to the vector control inverter 42 a or 42 b for the driving motor 16 connected to the driven travel wheel 14 A on the side with an advancing predictive travel distance, to decrease the driving rotation speed.
  • the driving rotation speed of the driving motor 16 for the side moving ahead is decreased and the side moving ahead moves thereafter slower than the delayed side so that the skewed attitude can be corrected according to the predictive travel distance preemptively and gradually to final complete elimination.
  • the automatic attitude controller 79 executes the attitude correction control for the movable rack 11 , where the driving rotation speeds of the respective driving motors 16 are controlled based on the detected travel distances of both the driven travel wheels 14 A, so as to eliminate the deviation of the travel distances of both the driven travel wheels 14 A.
  • an automatic widthwise shift control unit 80 is provided with a 3rd adder 92 that adds the magnetic intensity at the HP position measured by the HP magnetic detection unit 62 a and the magnetic intensity at the OP position measured by the OP magnetic detection unit 62 b to determine the total magnetic intensity, and a previous magnetic intensity memory 93 that stores the total magnetic intensity determined by the 3rd adder 92 during the travel stop time with time-delay (after elapse of a definite time by a timer from the activation of the relay RY-S).
  • a 1st comparator 94 that detects existence or non-existence of magnetic intensity at the HP position to be measured by the HP magnetic detection unit 62 a
  • a 2nd comparator 95 that detects existence or non-existence of magnetic intensity at the OP position to be measured by the OP magnetic detection unit 62 b ; and when the relay RY-S (stop command) is activated, if non-existence of magnetic intensity is detected by the 1st comparator 94 or the 2nd comparator 95 , an alarm signal is output to the alarm lamp 43 ; and when the relay RY-S (stop command) is activated, if existence of magnetic intensity is detected by the 1st comparator 94 and the 2nd comparator 95 , the aforedescribed reset signal is output.
  • a widthwise shift detector 96 that determines the widthwise shift in the transverse B of the travel path 10 generated by the current travel (the difference between the total magnetic intensities is converted to the widthwise shift) from the difference between the total magnetic intensity determined by the 3rd adder 92 and the previous total magnetic intensitiestored in the previous magnetic intensity memory 93 , when the relay RY-S (stop command) is activated.
  • a 3rd speed commander 97 that outputs a pre-set commanded speed value to one of the driven travel wheels 14 A
  • a 4th speed commander 98 that outputs a pre-set commanded speed value to the other driven travel wheel 14 A, whose execution is initiated if the relay RY-W-OP or the relay RY-W-HP is activated, AND the relay-F (advancing command) or the relay RY-B (retreating command) is activated.
  • the commanded speed value is output to the HP vector control inverter 42 a as follows. If the relay RY-W-OP is activated, the commanded speed value output from the 3rd speed commander 97 , and if the relay RY-W-HP is activated, the commanded speed value output from the 4th speed commander 98 is requested, and the commanded speed value is selected by the relay RY-F (advancing command), the commanded speed value inverted to a negative value is selected by the relay RY-B (retreating command), and the commanded speed value of “0” is selected, and output by the relay RY-S (stop command).
  • the commanded speed value is output to the OP vector control inverter 42 b as follows. If the relay RY-W-OP is activated, the commanded speed value output from the 4th speed commander 98 , and if the relay RY-W-HP is activated, the commanded speed value output from the 3rd speed commander 97 is requested, and the commanded speed value is selected by the relay RY-F (advancing command), the commanded speed value inverted to a negative value is selected by the relay RY-B (retreating command), and the commanded speed value of “0” is selected, and output by the relay RY-S (stop command).
  • a frequency detector 99 that counts the number of actions of the relay RY-W-OP or the relay RY-W-HP, namely determines the frequency of the executions of travels correcting the widthwise shift, and if the frequency exceeds the pre-determined frequency, outputs a caution signal to the caution lamp 44 .
  • the frequency detector 99 may determine the number of the executions of travels correcting the widthwise shift, and if the number exceeds the pre-determined number, outputs a caution signal.
  • a setting method of the commanded speed value output from the 3rd speed commander 97 and the 4th speed commander 98 is similar to the setting method of the commanded speed value output from the 1st speed commander 83 and the 2nd speed commander 84 of the semi-automatic widthwise shift control unit 78 .
  • the magnitude of the widthwise shift to be corrected is set at the maximum width that can be corrected by a single travel, namely a travel across the width of the work corridor S, and the difference of the total magnetic intensity determining the widthwise shift in the transverse direction B of the travel path 10 is correlated with the set maximum width.
  • the correctable widthwise shift by a single travel is set at the maximum correctable width in the above automatic widthwise shift control unit 80 , it may be set at 1 ⁇ 2 of the same as in the case of the semi-automatic widthwise shift control unit 78 .
  • the widthwise shift control is executed at the next and at the second travels to eliminate completely the deviation with 2 travels. It is further possible to eliminate the widthwise shift with 3 or more repeated travels.
  • the magnet 31 is detected by the respective HP and OP magnetic sensors 35 , and if the difference between the detected total magnetic intensity and the total magnetic intensitiestored at the previous travel stop exceeds a pre-determined value, namely if a widthwise shift above a pre-determined value is detected, the relay RY-W-OP is activated if a correction to the OP side is determined to be necessary, and the relay RY-W-HP is activated if a correction to the HP side is determined to be necessary.
  • a widthwise shift occurs, a widthwise shift control execution signal is output to the main control panel 38 , the occurrence of the widthwise shift is counted.
  • a caution signal is output to light up the caution lamp 44 , judging that the movable rack 11 is suffering from frequent widthwise shifts. Further, if the magnetic sensitivity of either of the HP or OP magnetic sensor 35 is lost, namely if the magnet 31 is not detected, it is so judged that the automatic widthwise shift control is malfunctioning and a widthwise shift has occurred which cannot be corrected automatically. Then, an alarm signal is output recommending the activation of the HP shift button switch 54 or the OP shift button switch 55 , and an alarm lamp 43 is lighted up.
  • a positive commanded speed value output from the 3rd speed commander 97 is output to the HP vector control inverter 42 a
  • a positive commanded speed value output from the 4th speed commander 98 is output to the OP vector control inverter 42 b
  • the movable rack controller 41 controls to drive the HP and OP driving motors 16 according to the commanded speed values so that the movable rack 11 advances and shifts to the OP side by a pre-determined width.
  • a negative commanded speed value output from the 3rd speed commander 97 is output to the HP vector control inverter 42 a
  • a negative commanded speed value output from the 4th speed commander 98 is output to the OP vector control inverter 42 b
  • the movable rack controller 41 controls to drive the HP and OP driving motors 16 according to the commanded speed values so that the movable rack 11 retreats and shifts to the OP side by a pre-determined width.
  • the relay RY-W-HP when the relay RY-W-HP is activated, if the relay RY-F (advancing command) is activated, a positive commanded speed value output from the 4th speed commander 98 is output to the HP vector control inverter 42 a , a positive commanded speed value output from the 3rd speed commander 97 is output to the OP vector control inverter 42 b , and the movable rack controller 41 controls to drive the HP and OP driving motors 16 according to the commanded speed values so that the movable rack 11 advances and shifts to the HP side by a pre-determined width.
  • a negative commanded speed value output from the 4th speed commander 98 is output to the HP vector control inverter 42 a
  • a negative commanded speed value output from the 3rd speed commander 97 is output to the OP vector control inverter 42 b
  • the movable rack controller 41 controls to drive the HP and OP driving motors 16 according to the commanded speed values so that the movable rack 11 retreats and shifts to the HP side by a pre-determined width.
  • the speed control unit 75 switches to output commanded speed values for the HP vector control inverter 42 a and the OP vector control inverter 42 b respectively, which are output from the forced driving unit 77 , the semi-automatic widthwise shift control unit 78 , the automatic attitude controller 79 and the automatic widthwise shift control unit 80 , by use of the relay RY-FOR (to select “forced”), the relay RY-AUTO (to select “automated”) and the relay RY-W (widthwise shift control underway).
  • the output signal of the forced driving unit 77 and the semi-automatic widthwise shift control unit 78 is output when the relay RY-FOR is activated
  • the output signal of the automatic attitude controller 79 is output when the relay RY-AUTO is activated and the relay RY-W is NOT activated
  • the output signal of the automatic widthwise shift control unit 80 is output when the relay RY-AUTO is activated and the relay RY-W is also activated.
  • a pair of the HP and OP driving motors 16 are started to rotate respectively the driven travel wheels 14 A.
  • a driving force is given to the movable rack 11 to travel on the travel path 10 , and the remaining travel wheels 14 follow rotating passively. Therefore, by means of a detection control system such as the proximity sensor 37 a installed between the movable racks 11 , the movable rack 11 can be stopped at the destination of the stop point P 6 without colliding the same against a movable rack 11 standing at the stop point P 7 .
  • the numbers of passages of the slits 28 a and 28 b formed on the turning unit 28 can be counted by the photoelectric switches 29 a and 29 b , and input to the control panel 20 .
  • the control panel 20 counts the pulses output from both the pulse encoders 21 , calculates the travel distances of the respective driven travel wheels 14 A, and compares them. In the current example, the travel distance of the HP driven travel wheel 14 A is larger (ahead), and the travel distance of the OP driven travel wheel 14 A is smaller (behind).
  • control panel 20 Based on the comparison, the control panel 20 outputs a control signal to reduce the driving rotation speed to the driving motor 16 connected to the driven travel wheel 14 A on the side whose travel distance is ahead, namely to the vector control inverter 42 a for the driving motor 16 connected with the HP driven travel wheel 14 A. This reduces the driving rotation speed of the HP driving motor 16 and the HP side moves slower than the other side, so that the skewed attitude is gradually corrected to final complete elimination.
  • a predictive travel distance can be obtained based on the travel distance and the time elapsed until the difference in the accumulated numbers of pulses exceeds the pre-set value, and a control signal to reduce the driving rotation speed is output to the vector control inverter 42 a or 42 b for a driving motor 16 connected to the driven travel wheel 14 A on the side whose predictive travel distance is ahead.
  • the movable rack 11 can travel keeping the orthogonal attitude toward the travel path 10 .
  • the magnet 31 is measured by the HP and OP respective magnetic sensors 35 , and if the deviation between the total magnetic intensity measured by the HP and OP magnetic sensors 35 and the previous total magnetic intensity is generated, this is recognized as generation of a widthwise shift, and then at the next travel control signals for differentiated rotation speeds are output to the vector control inverters 42 a or 42 b for the driving motors 16 connected to the driven travel wheels 14 A in order to eliminate the widthwise shift. Therefore the widthwise shift can be eliminated while the rack travels across the work corridor S. At this time, the movable rack 11 to travel following the movable rack 11 , which is subjected to the widthwise shift control, is started with a delay of the pre-determined time.
  • a worker can move the movable rack 11 compulsorily using the operation panel 40 .
  • the magnet 31 is measured by the HP and OP respective magnetic sensors 35 , and if a widthwise shift above a pre-determined value is detected from the measured total magnetic intensity, a travel route of the movable rack to eliminate the widthwise shift is determined, and the rotation speeds of the respective driving motors 16 are controlled so that the travel route be followed at the next travel and the widthwise shift of the movable rack 11 can be corrected. Consequently there is no need to construct a detectable sheet rail target along the travel path 10 and inconveniences accompanied by the construction can be avoided.
  • a movable rack 11 implements a widthwise shift correction travel, and the movable rack 11 turns toward the direction to which the widthwise shift should be corrected for this purpose, a possible collision between the backward edge of the skewed movable rack 11 and the following movable rack 11 can be avoided by delaying the start of the travel of a following another movable rack 11 for a certain time period.
  • the HP and OP driving motors 16 are driven to eliminate a widthwise shift, a trouble caused by a phenomenon that, if a driven travel wheel 14 A is stopped and the other driven travel wheel 14 A is moved around this axis point, the first driven travel wheel 14 A is dragged to move uncontrollably off the travel route, can be avoided by starting both the driving motors 16 above a pre-determined rotation speed.
  • a caution lamp 44 is lighted up and a worker can recognize that the widthwise shift occurs frequently at the movable rack 11 .
  • he/she can instruct re-learning of the values of travel distance per pulse to be set at the first counter 65 and the second counter 66 .
  • the widthwise shift control of the movable rack 11 is conducted by detecting the magnets 31 disposed at each stop position of the movable racks 11 by the magnetic sensors 35 , requiring only the disposition of the magnets 31 at the stop positions of the respective movable racks 11 .
  • the construction thereof can be simpler than the that of the conventional sheet rail member to be detected.
  • the rotation speeds of the respective driving motors 16 are controlled by the movable rack controller 41 of the movable rack 11 so that the rack follows the travel route determined to decrease the widthwise shift to the HP direction to shift the movable rack 11 to the HP direction in the transverse direction B by a pre-determined width; and when the OP shift button switch 55 is activated, the rotation speeds of the respective driving motors 16 are controlled by the movable rack controller 41 of the movable rack 11 so that the rack follows the travel route determined to decrease the widthwise shift to the OP direction to shift the movable rack 11 to the OP direction by a pre-determined width.
  • the width of the widthwise shift to be eliminated by the activation of the HP shift button switch 54 or the OP shift button switch 55 is set within the given width that can be corrected during the travel across the work corridor S, it can be prevented that the rack stops with a skewed attitude by reason of detection of a movable rack 11 in the traveling direction can be avoided during the correction of the widthwise shift. If the movable rack 11 is in a skewed attitude as above, the width of the work corridor S in the travel direction A becomes narrow and handling of the goods becomes difficult.
  • the magnet 31 is not detected when the rack 11 stops to travel, it is so judged that the automatic widthwise shift control is malfunctioning and a widthwise shift has occurred which cannot be corrected automatically, and an alarm lamp 43 is lighted up. A worker can recognize the direction of the widthwise shift of the rack by the alarm, and is urged to activate the HP shift button switch 54 or the OP shift button switch 55 .
  • the attitude control is conducted during a travel of the movable rack 11 by the movable rack controller 41 , and therefore, it can be avoided that the movable rack 11 stops with a skewed attitude can be avoided.
  • the movable rack 11 or stationary rack 3 is constituted of the lower frame unit 12 or 4 , and the rack unit 13 or 5 .
  • a movable rack 11 of a carriage type or a stationary rack 3 of a platform type without the rack unit 13 and 5 may be used.
  • the uppermost storage compartment 13 e and 5 a of the movable rack 11 and stationary rack 3 are open upward in this embodiment, but the movable rack 11 and stationary rack 3 having a roof on the top may be used.
  • the magnets 31 is buried in the floor, but thin magnets 31 , over which a vehicle easily rides, may be laid on the floor surface 1 a.
  • the driving motor 16 drives a pair (2) of the driven travel wheels 14 A, however, it is possible to arrange such that the driving motor 16 drives only one driven travel wheel 14 A. Moreover, it may be possible to apply a direct driving system where a reducing gear is directly connected to the end of the drive wheel shaft of a driven travel wheel 14 A and the driving motor 16 is directly connected to the reducing gear.
  • the travel wheels 14 are used as a supporting/running device, however, a roller chain type (a caterpillar type) supporting/running device may also be applicable.
  • a singularity of the roller chain should be provided at each side of the movable rack 11 in the transverse direction B extending over the entire length thereof in the travel direction A, or a plurality of roller chains should be provided extending over the entire length in the travel direction A in a divided manner.
  • a pulse encoder 21 is used as a travel distance measuring device, and two-sets measuring system, where outer slits 28 a and inner slits 28 b are formed on the rotating body 28 and an outer photoelectric switch 29 a facing the outer slits 28 a and an inner photoelectric switch 29 b facing the inner slits 28 b are provided, is exemplified.
  • one-set measuring system or three or more-sets measuring system may also be used.
  • the pulse encoder 21 uses a detection wheel unit 27 in order to measure the travel distance, but it is also possible to measure the driving rotation amount of the driven travel wheel 14 A therefor. Moreover, the pulse encoder 21 detects the rotation of the detection wheel unit 27 , instead it may be directly connected to the rotating shaft of the driving motor 16 (an example of a rotation driving device) to measure the travel distance of the movable rack 11 .
  • the magnetic sensor 35 is used to detect a widthwise shift, however the widthwise shift may also be detected by such an arrangement that a plurality of regressive reflecting type photosensors are provided at the forward and backward surfaces of the movable rack 11 facing the opposing movable racks 11 , and the reflectors be provided at the opposing movable racks 11 facing the photoelectric sensors, so that a widthwise shift can be detected by detecting the deactivation of the photoelectric sensor due to misalignment of the movable racks 11 .
  • the magnets 31 are disposed within the width of the movable rack 11 , but they may be disposed outside the width of the movable rack 11 .
  • goods are delivered and stored in and out of the storage compartment 13 e of the movable rack 11 and the storage compartment 5 a of the stationary rack 3 by means of pallets, but box containers may also be delivered and stored.
  • FIG. 1 is a plan view of a movable rack system of an embodiment of the present invention
  • FIG. 2 is a plan view showing the disposition of the magnets in the movable rack system
  • FIG. 3 is a side view of the movable rack system
  • FIG. 4 is a partial cutaway plan view of an important part of a movable rack in the movable rack system
  • FIG. 5 is a longitudinal sectional side view of the part of a rotation driving device and a travel distance measuring device of the movable rack in the movable rack system;
  • FIG. 6 is a longitudinal sectional side view of the part of a widthwise shift detection means of the movable rack in the movable rack system;
  • FIG. 7 is a longitudinal sectional front view of the part of the travel distance measuring device and the widthwise shift detection means of the movable rack in the movable rack system;
  • FIG. 8 is a longitudinal sectional front view of a travel wheel of the movable rack in the movable rack system
  • FIG. 9 is an arrangement plan of switches of an operation panel of the movable rack in the movable rack system
  • FIG. 10 is illustrations describing function of the switches on the operation panel of the movable rack in the movable rack system
  • FIG. 11 is a block diagram of controlling of the movable rack in the movable rack system
  • FIG. 12 is a block diagram of a forced travel control unit of a movable rack controller in the movable rack system
  • FIG. 13 is a block diagram of a forced driving unit of the movable rack controller in the movable rack system
  • FIG. 14 is a block diagram of a semi-automatic widthwise shift control unit of the movable rack controller in the movable rack system;
  • FIG. 15 is a block diagram of an automatic attitude controller of the movable rack controller in the movable rack system
  • FIG. 16 is a block diagram of an automatic widthwise shift control unit of the movable rack controller in the movable rack system.
  • FIG. 17 is illustrations concerning determination of a commanded speed value to be set at a speed commander of the semi-automatic widthwise shift control unit and the automatic widthwise shift control unit of the movable rack controller in the movable rack system.

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US13/257,914 2009-03-27 2009-03-27 Moving shelf equipment Active 2029-08-21 US8607911B2 (en)

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US20120006765A1 (en) 2012-01-12

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